Flooring system having sub-panels with complementary edge patterns

ABSTRACT

Laminated flooring planks include decorative motifs, mechanically embossed-in-registration surface textures, recessed perimeters, and locking mechanisms. Adjacent planks substantially aligned allow embossed-in-registration patterns to be substantially continuous across adjacent flooring panels. The recessed perimeter prevents the edges of the flooring panel from prematurely wearing. Individual planks within the flooring system may comprise at least one partial sub-panel having a decorative motif and/or embossed surface texture (i.e., pattern)that is complementary with a pattern of a neighboring partial sub-panel or plank. Each plank may include edge patterns adjacent a portion of an edge of the plank and at least one bulk pattern adjacent the edge patterns. Edge patterns within a plank and of planks within a flooring system are substantially identical to each other. Bulk patterns form a substantially continuous pattern within an individual plank when adjacent a plank.

This application incorporates by reference application Ser. No.10/689,510, filed on Oct. 21, 2003, entitled FLOORING SYSTEM HAVINGSUB-PANELS WITH COMPLEMENTARY EDGE PATTERNS, which is aContinuation-in-Part of application Ser. No. 10/374,751, filed on Feb.27, 2003, entitled “FLOORING SYSTEM HAVING COMPLEMENTARY SUB-PANELS”(Attorney Docket No. 5724.017.22), which is a Continuation-in-Part ofco-pending application Ser. No. 10/352,248, filed on Jan. 28, 2003,entitled “FLOORING SYSTEM HAVING COMPLEMENTARY SUB-PANELS” (AttorneyDocket No. 5724.017.21), which is a Continuation-in-Part of co-pendingapplication Ser. No. 10/137,319, filed on May 3, 2002, entitled“EMBOSSED-IN-REGISTER PANEL SYSTEM” (Attorney Docket No. 5724.017.00),and incorporates by reference co-pending application Ser. No.09/903,807, filed on Jul. 31, 2001, entitled “EMBOSSED-IN-REGISTERMANUFACTURING PROCESS” (Attorney Docket No. 5724.016.00) and U.S. Pat.No. 6,401,415, filed on Dec. 13, 1999, entitled “DIRECT LAMINATEDFLOOR”, for all purposes as if fully set forth herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to laminated materials. More particularly,the present invention relates to a flooring system of interlockedlaminated materials having decorative motifs and surface textures thatare mechanically embossed in registration with their decorative motifs.

2. Discussion of the Related Art

Because of their look and feel, traditional building and finishingflooring materials such as fine woods, slate, granite, stones, brick,and concrete are generally preferred by consumers. However, suchtraditional building and finishing flooring materials tend to beexpensive to produce and install. For example, while a solid wood floorhas a highly valued luxurious appearance, the materials and laborrequired to install such floors can be prohibitively expensive.

Many alternatives to traditional building and finishing flooringmaterials are available, including laminates such as high-pressurelaminates (HPL), direct-pressure laminates (DPL), andcontinuous-pressure laminates (CPL). However, such alternativestypically do not possess the realistic look and texture of thetraditional building and finishing flooring materials. For example, mostalternatives having an outer surface with a wood motif look fake and canreadily be identified as something other than authentic wood.Furthermore, while high quality HPL, DPL, or CPL boards may visuallylook like wood, their textures readily reveal that they are not.

One problem with most alternatives to traditional building and finishingflooring materials is that their surface textures do not match theirdecorative motifs. For example, visual depictions of wood knots inalternative flooring materials are not matched with surface texturescharacteristic of the wood knots. Accordingly, the attractiveness ofthese alternative materials is significantly reduced.

One approach used to match the surface texture of alternative flooringmaterials to their decorative motifs includes a technique known aschemical embossing. In chemical embossing, the surface texture of thealternative material is developed by chemically reacting an ink thatforms the decorative motif with an agent added to a sub-surface layer.While somewhat successful, the resulting surface texture tends to lackthe textual sharpness and three-dimensional characteristics oftraditional materials.

As an alternative to the traditional building and finishing flooringmaterials laminated materials may be mechanically embossed to produce asurface texture. See, for example U.S. patent application Ser. No.09/903,807 and U.S. Pat. No. 6,401,415, which are hereby incorporated byreference. Such methods produce embossed-in-registration laminatedmaterials having decorative motifs and matching high-qualitythree-dimensional textures. Embossed-in-registration laminated materialsrequire accurate registration of mechanical embossment and thedecorative motif. An advantage of embossed-in-registration laminatedmaterials is that they can realistically reproduce the look and feel oftraditional products.

No matter what type of flooring system is used, the flooring system mustbe easily moved to a work site while being easy and quick to install. Tothis end, assembly and locking mechanisms may be incorporated withinflooring systems to facilitate on-site installation. One type ofassembly and locking mechanism is the tongue and groove system used forconnecting panels. It is understood that such tongue and groove systemsare disclosed in Cherry, U.S. Pat. No. 2,057,135, and in Urbain, U.S.Pat. No. 2,046,593. For example, FIG. 1 can be interpreted to illustratea tongue and groove system 11 that uses clips 12 to secure panelstogether.

Another type of assembly and locking mechanism is understood to bedisclosed in Chevaux, U.S. Pat. No. 3,946,529 where a flooring system 13appears to be connected using a tongue and groove system arrangedunderneath the flooring, reference FIG. 2.

Still another assembly and locking mechanism is taught in Kajiwara, U.S.Pat. No. 5,295,341. There, it is understood that laminated boards areprovided with a snap-together system such as a groove-tongue joint. As aresult the laminated boards can be assembled without glue. Referring toFIG. 3, the laminated boards are provided with a locking means in theform of a groove connector 16, and a tongue connector 18. The grooveconnector 16 has forwardly protruding grooves 20, while the tongue 18 isprovided with a pair of forwardly diverging sidewalls 22 and 24 that areseparated by an elongated groove 26. The sidewalls include rear lockingsurfaces 28 and 36. The sidewalls can be compressed together to enablelocking.

Another type of assembly and locking mechanism is the snap-togetherjoint is suggested in Martensson, U.S. Pat. No. 6,101,778. As shown inFIG. 4, it is understood that laminated boards are provided with alocking means comprised of a groove 6 and a tongue 7 that form atongue-groove assembly. The groove 6 and tongue 7 may be made of watertight material and snapped together with a portion 9 fitting in a slot4.

While the aforementioned assembly and locking mechanisms have provenuseful, they have not been used with embossed-in-registration laminatesystems in which embossed-in-registration decorative motifs or graphicsalign across joints between the individual embossed-in-registrationlaminates. This significantly detracts from the visual and texturalimpression of systems comprised of embossed-in-registration laminateboards. Therefore, a new embossed-in-registration laminate system inwhich the visual and textural patterns cross joints while retaining theembossed-in-registration aspects would be beneficial. Even morebeneficial would be an embossed-in-registration laminate systemcomprised of interlocking embossed-in-registration laminate boards inwhich the visual and textural patterns cross joints while retainingembossed-in-registration aspects.

Further, the aforementioned flooring systems have a relatively lowability to resist wear. While not wishing to be bound by any particulartheory, it is hypothesized that premature aging (wear) begins at or nearthe perimeter edges and/or along tongue and groove lines. Theaforementioned flooring systems have a substantially even (level)surface texture such that the center and perimeter of each panel contactusers (e.g., pedestrians) an equal amount. The perimeter of each panel,however, is substantially weaker than the center of the panel andtherefore deteriorates first.

In addition, flooring systems typically do not have decorative motifs orpattern designs that are longer than the length of a plank. For example,in a flooring system designed to reproduce a wood floor having woodstrips, the length of the wood strip pattern is typically equal to orshorter than the length of a single plank. This is desirable in relatedart flooring systems because it does not require the installer to planmore than one plank beyond the plank being installed.

Accordingly, there is a need for a workable method of fabricatingalternative building or finishing materials where the alternatives havethe realistic look and feel of traditional products and have anincreased capacity to resist premature wear, and in which the minimumnumber of planks is used maintained while still being able to createdesign motifs or pattern elements with a length greater than that of asingle plank.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed toembossed-in-registration flooring system that substantially obviates oneor more of the problems due to limitations and disadvantages of therelated art.

An advantage of the present invention provides anembossed-in-registration flooring system including individual adjacentflooring planks having embossed-in-registration decorative motifs whereat least one of a surface texture and decorative motif is substantiallyaligned between adjacent flooring planks.

Another advantage of the present invention provides anembossed-in-registration flooring system including interlocked flooringplanks having embossed-in-registration decorative motifs where at leastone of a surface texture and decorative motif is substantially alignedbetween adjacent flooring planks such that substantially continuousembossed-in-registration patterns are formed across the interlockedflooring planks.

Another advantage of the present invention provides anembossed-in-registration flooring system may, for example, includeflooring planks wherein a surface of a perimeter of each individualflooring plank may be recessed such that an upper surface of theperimeter of the flooring planks is below a portion of an upper surfaceof the flooring planks surrounded by the perimeter.

Another advantage of the present invention provides a plank comprising aplurality of sides defining a perimeter; a plurality of edge patternsarranged proximate at least one first portion of the perimeter, whereinat least two of the plurality of edge patterns are substantiallyidentical; and at least one bulk pattern arranged adjacent the pluralityof edge patterns and proximate at least one second portion of theperimeter, wherein at least one bulk pattern and an edge patternadjacent the at least one bulk pattern forms a substantially continuouspattern.

Another advantage of the present invention provides a flooring system,comprising at least two planks adjacent each other along a predetermineddirection, wherein each plank comprises: a plurality of sides defining aperimeter; a plurality of edge patterns arranged proximate at least onefirst portion of the perimeter, wherein at least two of the plurality ofedge patterns are substantially identical; and at least one bulk patternarranged adjacent the plurality of edge patterns and proximate at leastone second portion of the perimeter, wherein at least one bulk patternand an edge pattern adjacent the at one least bulk pattern formssubstantially continuous pattern; herein edge patterns of the at leasttwo planks form a substantially continuous pattern.

A further advantage of the present invention provides a floor panel,comprising a plurality of sides defining a perimeter; a surface havingthereon a decorative motif, said decorative motif comprising at leasttwo edge patterns adjacent each of the sides of the panel and at leastone bulk pattern in the interior of the panel and adjacent the edgepattern on each side, wherein at least one edge pattern along a side issubstantially identical to the edge pattern in a corresponding positionalong an opposite side; and wherein at least one portion of thedecorative motif along a side is substantially different from thecorresponding portion of the decorative motif along an opposite side.

Additional features and advantages of the invention will be set forth inthe description which follows, and in part will be apparent from thedescription, or may be learned by practice of the invention. These andother advantages of the invention will be realized and attained by thestructure particularly pointed out in the written description and claimshereof as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention andtogether with the description serve to explain the principles of theinvention.

In the drawings:

FIG. 1 illustrates a related art assembly and locking mechanism;

FIG. 2 illustrates another related art assembly and locking mechanism;

FIG. 3 illustrates yet another related art assembly and lockingmechanism;

FIG. 4 illustrates still another related art assembly and lockingmechanism;

FIG. 5 illustrates a perspective view of components in anembossed-in-registration flooring plank according to the principles ofthe present invention;

FIG. 6 illustrates a press machine capable of fabricatingembossed-in-registration flooring planks in accordance with theprinciples of the present invention;

FIG. 7 illustrates an embossed-in-registration flooring plank in oneaspect of the present invention;

FIG. 8 illustrates a top view of a system of embossed-in-registrationflooring planks in another aspect of the present invention;

FIG. 9 illustrates a cross-sectional view along line 9-9 shown in FIG.8;

FIG. 10 illustrates a top view of a system of embossed-in-registrationflooring planks in yet another aspect of the present invention;

FIG. 11 illustrates a cross-sectional view along line 11-11 shown inFIG. 10;

FIGS. 12A and 12B illustrate schematic views including a perimetersurface portion of a flooring plank in accordance with the principles ofthe present invention;

FIGS. 13A and 13B illustrate a flooring system in still another aspectof the present invention;

FIGS. 14A-14C illustrate an exemplary plank of a flooring system instill another aspect of the present invention+and

FIGS. 15A-15E illustrate an exemplary method of forming patterns on aflooring plank in accordance with the principles of the presentinvention.

FIGS. 16A-16E illustrate an alternative exemplary method of formingpatterns on a flooring plank in accordance with the principles of thepresent invention.

FIG. 17 illustrates an alternative exemplary method of forming patternson a flooring plank in accordance with the principles of the presentinvention.

FIG. 18 illustrates an alternative exemplary method of forming patternson a flooring plank in accordance with the principles of the presentinvention.

FIG. 19 illustrates an alternative exemplary method of forming patternson a flooring plank in accordance with the principles of the presentinvention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings.

FIG. 5 generally illustrates components of a flooring plank according tothe principles of the present invention.

Referring to FIG. 5, an embossed-in-registration flooring system may,for example, include at least one flooring plank. In one aspect of thepresent invention each flooring plank may include a board substrate 34made out of a substrate material (e.g., a medium or high densityfiberboard, chipboard, etc.), at least one base sheet 36 (e.g., a kraftpaper sheet) impregnated with predetermined resins and arranged overand/or under the board substrate 34, a decorative paper sheet 38 about0.15 mm thick and impregnated with a polymerizable resin (e.g., phenolssuch as melamine) arranged over the board substrate, and at least oneprotective overlay sheet 30 arranged over the decorative paper sheet 38.In one aspect of the present invention, each protective overlay sheet 30may be formed from a highly resistant paper impregnated with a melaminesolution containing corundum (Al₂O₃), silica, etc. In another aspect ofthe present invention, different papers may be arranged between thedecorative paper sheet 38 and the board substrate 34. In one aspect ofthe present invention, the at least one protective overlay sheet 30 andthe base sheet 36 may be impregnated with a resin. In another aspect ofthe present invention the resin impregnating the at least one protectiveoverlay sheet 30 and the base sheet 36 may be different from themelamine resin used to impregnate the decorative paper sheet 38.

In one aspect of the present invention, flooring planks within aflooring system may be fabricated from substantially the same paper,resin, etc. For example, flooring planks within a flooring system may befabricated using paper made from substantially the same paper fibers(having, for example, substantially the same ash content, color, andorientation) on the same on the same paper making machine. Further,flooring planks within a flooring system may be fabricated using paperoriginating from a single, contiguous section on the manufacturingspool. All of the aforementioned paper use restrictions that may beemployed in fabricating flooring planks of a flooring system ensure thatimpregnated papers will always have substantially the same finaldimensions after they are pressed and cured. In one aspect of thepresent invention, the warehousing of paper used to fabricated flooringplanks within a flooring system may be controlled such that the time,temperature, and humidity in which the paper is stored is maintained tofacilitate consistent flooring plank dimensions. In another aspect ofthe present invention, flooring planks within a flooring system may befabricated using cellulose paste made from the same manufacturer. In yetanother aspect of the present invention, flooring planks within aflooring system may be fabricated using resins made from the samemanufacturer. In still another aspect of the present invention, theresins may contain powder originating from substantially the samesource, have substantially the same chemical and physical qualities, andbe mixed in the same reactor. Further, flooring planks within a flooringsystem may be fabricated using resins have a substantially constantsolids content. All of the aforementioned resin use restrictions thatmay be employed in fabricating the flooring planks ensure thatimpregnated papers will always have substantially the same finaldimensions after they are pressed and cured. In still another aspect ofthe present invention, each of the flooring planks within a flooringsystem may be fabricated using substantially the same impregnationprocess. For example, when dipping the various sheets of paper intomelamine resin, the paper should experience a constant, uniform melamineload. Further, a band tension and oscillation of the impregnationmachine should be precisely controlled as they influence the degree towhich the various paper sheets are impregnated with the resin.

According to the principles of the present invention, the aforementionedsheets and substrates may be fabricated into an embossed-in-registrationflooring system including a plurality of interlocking flooring planks.To produce such a flooring system, a press machine, such as a pressmachine shown in FIG. 6, may be used to mechanically emboss eachflooring plank in registration with a decorative motif arranged on thedecorative paper sheet 44.

Referring to FIG. 6, the press machine may, for example, include a base42, a top press 54, and an upper press plate 56. In one aspect of thepresent invention, the upper press plate may include an embossingpattern (e.g., a three-dimensionally textured surface). Accordingly, theembossing pattern may, for example, include elevated ridges, dots,depressions, etc., of any design capable of being aligned with adecorative motif formed on the decorative paper sheet 44.

According to the principles of the present invention, the impregnateddecorative paper sheet 44 arranged on the board substrate 40 must beaccurately positioned relative to the embossing pattern of the upperpress plate to enable an embossed-in-registration flooring plank. In oneaspect of the present invention, alignment between the embossing patternof the press plate and the decorative motif must be ensured when thepress is in a locked position and the board is under pressure. Thedegree of control required may vary depending on the type of decorativemotif used. For example, alignment of a wood grainembossed-in-registration motif across adjacent embossed-in-registrationflooring planks requires a higher degree of alignment than alignment ofa wood grain embossed-in-registration motif that is not aligned withadjacent flooring planks.

Alignment between the decorative motif on the decorative paper sheet 44and the embossing pattern on the upper press plate 56 may be achieved byremoving about 2 to 3 millimeters of material around the perimeter ofthe board substrate 40 in a milling process thereby yielding severalreference planes (e.g., board edges) and a board substrate havingtightly controlled dimensions. Next, an impregnated decorative papersheet 44 having exterior dimensions about 8 or 10 mm smaller than theboard substrate 40 is arranged on the board substrate 40. In one aspectof the present invention, the impregnated decorative paper sheet 44 maybe arranged on the board substrate 40 using the board edges as alignmentmeans. In one aspect of the present invention, alignment marks may bearranged on the board substrate 40 and be alignable with alignment marksprovided on the decorative paper sheet 44.

In one aspect of the present invention, the decorative paper sheet 44may be attached to the board substrate 40 via static electricity. Afterthey are attached, the decorative paper sheet 44 and the board substrate40 are arranged on a carriage feeding into the press machine. The staticelectricity may substantially prevent the decorative paper sheet 44 frombeing accidentally displaced as the board substrate 40 is moved with thecarriage. In one aspect of the present invention, the carriage may bestopped just before it enters into the press machine such that thedecorative paper sheet 44 may be precisely arranged over the boardsubstrate 40 using, for example, tweezers (not shown). In another aspectof the present invention, the tweezers may be used to precisely arrangethe decorative paper sheet 44 over the board substrate 40 arranged onthe lower press plate. In one aspect of the present invention, thedecorative paper sheet 44, the at least one protective overlay sheet 46,and the optional base sheet 48 may be arranged over the board substrate40 prior to being arranged within the press machine. After thedecorative paper sheet 44 is arranged over the board substrate 40, thecarriage may be moved out of the press machine. Next, an alignmentsystem substantially aligns the decorative paper sheet 44/boardsubstrate 40 system with the embossing pattern in the upper press plate56. In one aspect of the present invention, the alignment system may usethe board edges to substantially align the decorative motif 44 with theembossing pattern on the upper press plate 56. The press machine may beoperated after the alignment is complete.

In one aspect of the present invention, after the components illustratedin FIG. 5 are arranged within the press machine and aligned with theembossing pattern, the various sheets and substrate may be pressed andcured for predetermined amount of time until the resins set, yielding anextremely hard and wear resistant flooring plank. For example, afterbeing inserted into the press machine and aligned with the embossingpattern, the board substrate 40, decorative paper sheet 44, protectiveoverlay sheet 46, and optional base sheet 48 may be heated at atemperature of about 160-220° C. and pressed together under a pressureof about 20-40 Kg/cm² for about 20 to 60 seconds. Accordingly, the toppress 54 presses the embossing pattern of the upper press plate 56 intothe decorative paper sheet 44 and board substrate 40 structure. Thecombination of the applied heat and pressure fuses the decorative papersheet 44 and the board substrate 40 together. The alignment systemensures that the decorative paper sheet 44 is substantially aligned withthe embossing pattern in the upper press plate 56. Accordingly, melamineresin within the various sheets may be cured and anembossed-in-registration plank may be produced.

In one aspect of the present invention, porosity within the fused piecemay be minimized by slowly curing the resins (e.g., the melamine).Accordingly, as the operating temperature is reduced, the time duringwhich the various sheets within the press machine are pressed isincreased. In another aspect of the present invention, as the pressplate 56 is heated to about 160-220° C. the embossing pattern includedwithin the press plate may expand. Accordingly, the embossing pattern onthe press plate 56 may be provided so as to compensate for the expansionof the pattern. Therefore, the dimensions of the embossing pattern areprovided such that they substantially correspond to the design of thedecorative motif when the resins within the components of FIG. 5 arecured.

According to the principles of the present invention, a mechanicallyembossed surface texture may be imparted to an individual flooring plankhaving a decorative motif. In one aspect of the present invention, themechanically embossed surface texture may be provided in registrationwith the decorative motif. Accordingly, an embossed-in-registrationflooring plank may be fabricated. In another aspect of the presentinvention, a plurality of embossed-in-registration flooring planks maybe joined together to form an embossed-in-registration flooring system.In yet another aspect of the present invention, at least a portion ofembossed-in-registration patterns of adjacent flooring planks may besubstantially aligned with each other to form substantially contiguousembossed-in-registration patterns across adjacent flooring planks withinthe flooring system.

While the embossed-in-registration process described above is suitablefor embossed surface textures that are less than about 0.2 mm deep,deeper surface textures may be problematic. Embossing patterns capableof imparting deep surface textures, for example, require relativelylarge press plate protrusions that tend to disturb the pressurehomogeneity applied across the board surface. This pressure disturbancecan cause distortions in the final product. In one aspect of the presentinvention, embossed surface textures may be formed greater than about0.2 mm deep by hollowing out the board substrate 40 at locations wheredeep surface textures are desired. In one aspect of the presentinvention, the hollowing out process may be performed before, during, orafter the perimeter of the board substrate 40 is milled as describedabove. In another aspect of the present invention, the board edges maybe used to locate the boundaries of the hollowed out portions of theboard substrate 40.

Referring to FIG. 7, an embossed-in-registration flooring plank 60,fabricated according to the process described above may optionallyinclude a protective padding layer 50 on one side. The mechanicallyembossed surface texture is registered with the decorative motif 68 ofthe decorative paper sheet 44. By registration, it is meant that theembossed surface texture is substantially aligned with the decorativemotif of the decorative paper sheet 44. By providing anembossed-in-registration flooring plank, a realistic representation of anatural material may provided to individual flooring planks. While thedecorative motif illustrated in FIG. 7 realistically represents theimage and texture of a wood grain, it should be appreciated that otherembossed-in-registration designs such as ceramic planks, concrete,marble, etc., may be produced.

According to the principles of the present invention, each of theindividual flooring planks may, for example, include at least onelocking mechanism.

In one aspect of the present invention, locking mechanisms may beincorporated within the board substrate 40 before the embossing patternis imparted to the surface of the board substrate 40 in registrationwith the decorative motif. Accordingly, locking mechanisms may befabricated within individual board substrates 40. Next, the lockingmechanisms may be used to join individual board substrates together toform a plank structure. The plank structure may then be inserted intothe press 54. After the embossing pattern is imparted to the plankstructure and the fused components are fused together, the plankstructure is removed from the press 54. Next, embossed-in-registrationflooring planks 60 within the fused plank structure are separated byunlocking the locking mechanisms. In one aspect of the presentinvention, cutting tools may be used to assist in the separation and toensure the decorative motif is not damaged.

In another aspect of the present invention, the locking mechanisms maybe incorporated within the board substrate 40 after the embossingpattern is imparted to the surface of the board substrate 40 inregistration with the decorative motif. Accordingly, a board substrate40 having relatively large dimensions of, for example, 4′×8′, may beembossed by the press 54. Next, the resulting embossed-in-registrationsubstrate may be cut into a plurality of individualembossed-in-registration flooring planks 60. In one aspect of thepresent invention, edges of the individual embossed-in-registrationflooring planks 60 may have smooth edges and precise dimensions. In oneaspect of the present invention, the cutting may be performed usingshaping tools, milling tools, cutting tools, breaking tools, etc. In oneaspect of the present invention, the board substrate may be cut by thepress machine. Accordingly, the board substrate 40 may be cut into units(e.g., strips) having dimensions of, for example, 300×300 mm, 400×400mm, 600×600 mm, 1,200×300 mm, 1,200×400 mm, etc. Next, the lockingmechanisms may be incorporated within the individualembossed-in-registration flooring planks 60. In one aspect of thepresent invention, the locking mechanisms may be hidden beneath thesurface of the flooring planks or they may be visible.

According to the principles of the present invention, the lockingmechanisms may be incorporated within the individualembossed-in-registration flooring planks 60 by aligning the at least oneof the board edges, alignment marks, decorative motifs, and surfacetextures of the flooring plank with a milling tool. By aligning themilling tool with any of the aforementioned alignable features, lockingmechanisms may be milled into the sides of the board substrates 40 suchthat, when flooring planks 60 are joined together the at least a portionof the decorative motifs form a continuous pattern and at least aportion of the embossed-in-registration patterns form a substantiallycontinuous surface texture across adjacent flooring planks.

According to the principles of the present invention, theembossed-in-registration flooring plank 60 may include a lockingmechanism 64 (e.g., at least one of a tongue and groove locking system,a snap-together locking system, etc.) extending along all four sides ofthe embossed-in-registration laminate 60. For example, a snap-togetherlocking system may be added to all four sides of theembossed-in-registration flooring plank 60 and used to connect multipleembossed-in-registration flooring planks 60 into anembossed-in-registration flooring system 300 (as shown in FIG. 8). Thenumber and location of locking mechanisms may depend on the desiredconfiguration of the embossed-in-registration flooring system. Forexample, when an embossed-in-registration flooring system abuts acorner, only two locking mechanisms are required (along the sides).

Referring to FIG. 8, the embossed-in-registration flooring planks A andB may, for example, include locking mechanisms along four sides (e.g.,along joints J1, J2, J3, and J4). Embossed-in-registration flooringplanks C and D may, for example, include locking mechanisms along foursides (e.g., along joints J1, J2, J3, and another joint not shown).

Embossed-in-registration flooring planks including the aforementionedlocking mechanisms may be securely attached together with or withoutglue to form an embossed-in-registration laminate system 300. Multipleembossed-in-registration flooring planks may be joined together toobtain any desired shape for flooring, planking, or the like. Theembossed-in-registration flooring planks may be joined to each othersuch that at least portions of embossed-in-registration patterns ofadjacent flooring planks are substantially aligned with each other andform a substantially continuous image and embossed surface textureacross flooring planks within a flooring system.

FIGS. 8 and 9 illustrate an exemplary embossed-in-registration flooringsystem 300 incorporating one type of locking mechanism on each of theindividual embossed-in-registration flooring planks 60. FIG. 9illustrates an exemplary embossed-in-registration flooring systemincluding flooring planks incorporating a snap-type tongue and groovelocking mechanism. In one aspect of the present invention, the snap-typetongue and groove locking mechanism may be integrated into the sidewallsof each embossed-in-registration laminate 60 so as to ensure thatembossed-in-registration patterns of adjacent flooring planks aresubstantially aligned with each other and substantially continuouswithin the flooring system.

FIG. 9 illustrates a cross sectional view of FIG. 8 taken along line9-9. As shown, the locking mechanism may be fabricated by forming agroove 230, a tongue 200, a channel 210, and a lip 220 along the edgesof the embossed-in-registration flooring planks 60. The lockingmechanisms on the embossed-in-registration flooring planks 60 may bejoined together by inserting the tongue 200 into the groove 230 of anadjacent embossed-in-registration flooring plank 60. Subsequently, thelip 220 is secured within channel 210, thereby joining adjacentembossed-in-registration flooring planks 60 into anembossed-in-registration flooring system 300. In one aspect of thepresent invention, the embossed-in-registration flooring planks 60labeled A, B, C and D may be joined together with or without glue. Itshould is appreciated that other types of locking mechanisms may beincorporated within the sides of the individual embossed-in-registrationflooring planks 60.

Referring back to FIG. 8, each of the embossed-in-registration flooringplanks 60 may, for example, exhibit an embossed-in-registration ceramicplank motif G1. The ceramic plank motif may comprise a plurality ofplanks in the shape of squares, rectangles, triangles, circles, ovals,any other shape or design that are separated by grout lines. In oneaspect of the present invention, widths of grout lines Wh, Wv, and theintraboard grout width W may be substantially equal. When incorporatingthe snap-type tongue and groove locking mechanism into theembossed-in-registration flooring planks 60 the grout width adjacent thejoints J1, J2, J3, and J4 on each embossed-in-registration laminate A,B, C, and D are approximately one-half the intraboard grout width W. Forexample, the vertical plank grout width (Wv) across joint J1 is made upof grout lines on embossed-in-registration laminates A, B, C and D, suchthat when the embossed-in-registration laminates A, B, C, and D arejoined at J1 the vertical grout width (Wv) is approximately equal to(W). Accordingly, the grout width on any individualembossed-in-registration flooring plank 60 adjacent a joint is one-halfof intraboard grout width (W). In another aspect of the presentinvention, the horizontal and vertical grout widths Wh and Wv may becontrolled such they are substantially equal to the dimensions of theintraboard grout width W. It should be appreciated, however, that thedimensions of the grout widths in the embossed-in-registration flooringplanks depend on the type of locking mechanism incorporated and thedecorative motif exhibited.

In addition to grout lines, many other decorative motifs may be used inthe embossed-in-registration flooring system of the present invention.Referring to FIGS. 10 and 11, a decorative motif exhibiting, forexample, a wood grain surface G2 substantially aligned across joints J5and J6 of adjacent flooring planks may be provided. According to theprinciples of the present invention, wood grain patterns generallyinclude more elements (e.g., wood grain lines, wood knot 423, etc.) thatextend to the perimeters of the flooring planks that need to be alignedthan ceramic plank motifs. Accordingly, aligning the wood grain motif isgenerally more difficult than aligning grout line portions of theceramic plank motifs. For example, aligning a first portion of a woodknot 423 on embossed-in-registration flooring plank E with a secondportion of the wood knot 423 on embossed-in-registration flooring plankF is generally more complex than aligning grout line widths acrossjoints of adjacent flooring planks. Accordingly, when fabricating alocking mechanism, consideration of all the graphic elements (e.g., woodgrains lines and wood knots 423) must be considered to ensure arealistic embossed-in-registration flooring system 400. In one aspect ofthe present invention, at least one portion of the decorative motif maybe used as an alignment marks ensuring consistent alignment of adjacentflooring planks.

In another aspect of the present invention, individual flooring plankswithin the embossed-in-registration flooring system 400 may be joinedtogether with a snap-type mechanical system as illustrated in FIG. 11depicting a cross sectional view of FIG. 10 along line 11-11. Again,alignment techniques used in the fabrication of the locking mechanismsuch that the embossed-in-registration laminate system 400 has a surfacetexture surface 423 that is substantially continuous across joints, J5and J6. Optionally, the embossed-in-registration laminates 60 have aprotective padding layer 70 under the base sheet 48.

FIGS. 12A and 12B illustrate schematic views of a flooring plank inaccordance with the principles of the present invention.

Referring to FIGS. 12A and 12B, an upper surface at the perimeter, P, ofeach embossed-in-registration flooring plank may be recessed below anupper surface at the portions of the flooring plank surrounded by theperimeter. An object O (e.g., a users shoe, a wheel, etc.) contactingthe major surface, Ms, of a flooring plank does not generally contactthe surface of the perimeter, Ps, due to the perimeter's recessedsurface. In one aspect of the present invention, the perimeter mayinclude a portion of the flooring plank extending from the edge of theflooring plank approximately 3.175 mm toward the center of the flooringplank. In another aspect of the present invention, the depth to whichthe surface of the perimeter of the flooring plank is recessed isapproximately 0.794 mm. In another aspect of the present invention, thesurface of at least one portion of the perimeter of a flooring plank maynot be recessed, as will be discussed in greater detail below withreference to FIG. 13.

Accordingly, the embossed-in-registration pattern may be provided to theedges of the flooring plank and may be aligned withembossed-in-registration patterns formed on adjacent flooring plankswhile the edges of each individual flooring plank may be prevented fromprematurely wearing.

Although it has been shown in FIGS. 8 and 10 that individual flooringplanks within a flooring system are substantially the same size andshape and are joined to each other such that each side of each flooringplank is joined to only one adjacent flooring plank, it should beappreciated that individual flooring planks within a flooring system mayvary in size (e.g., width and/or length) and shape (e.g., rectangular,square, triangular, hexagonal, etc.). In one aspect of the presentinvention, individual flooring planks may have complementary shapescapable of being assembled similar to a puzzle or mosaic. Further, oneaspect of the present invention contemplates that sides of individualflooring planks may contact more than one adjacent flooring plank.

In accordance with the principles of the present invention, flooringplanks within a flooring system may be arranged such that at least oneside of each plank includes at least one sub-panel adjacent at least twoother sub-panels. In another aspect of the present invention, each plankmay include, either entirely or partially, at least one sub-panel, aswill be described in greater detail below.

In FIG. 13A, for example, partial sub-panel 134A of plank 130A may be acomplementary sub-panel with respect to neighboring partial sub-panel136B of plank 130B, adjacent plank 130A. With this arrangement, thepartial sub-panels 134A and 136B may be made to appear as one unitarysub-panel.

Still referring to FIG. 13A, each of the planks 130A-F may comprise atleast three sub-panels wherein at least one of the sub-panels is aunitary sub-panel and at least two of the sub-panels are partialsub-panels. For example, 132A is a unitary sub-panel and 134A and 136Aare partial sub-panels.

In one aspect of the present invention, the unitary sub-panel 132A mayprovide a complete decorative motif with or without an embossed surfacetexture that may or may not be in registration with the decorativemotif. In another aspect of the present invention, the partialsub-panels 134A and 136A of a plank may provide separated, incompletedecorative motifs with or without embossed surface textures that may ormay not be in registration with the decorative motifs. In one aspect ofthe present invention, neighboring partial sub-panels of adjacent planksmay be complementary to each other such that they provide asubstantially complete decorative motif and/or surface texture andappear as a substantially continuous, unitary sub-panel. In one aspectof the present invention, complementary partial sub-panels may havecomplementary decorative motifs and/or embossed surface textures.Accordingly, when complementary partial sub-panels of adjacent planksare properly aligned, a substantially continuous (i.e., complete)decorative motif and/or embossed surface texture may be formed acrossneighboring complementary partial sub-panels. In one aspect of thepresent invention, sub-panels within a plank may or may not comprisesubstantially the same decorative motif and/or embossed surface texture.

FIG. 13B illustrates a schematic view of an exemplary plank 130 such asthat shown in FIG. 13A.

In one aspect of the present invention, portions of the perimetersurface of each plank may be recessed at locations where neighboringsub-panels are not complementary. In another aspect of the presentinvention, portions of the perimeter surface of each plank may benon-recessed at locations where neighboring sub-panels arecomplementary. Referring to FIG. 13B, portions of the upper surface ofthe perimeter “P” of each of the planks 130 indicated by referencenumeral 138 a may be slightly recessed compared to the major surface ofeach of the planks (see also FIG. 12B) to prevent premature wear of eachof the planks. Further, portions of the upper surface of the perimeterof each of the planks 130 indicated by reference numeral 138 b may benon-recessed and substantially coplanar with the major surface of thesub-panels. Recessing only portions of the perimeter surface of each ofthe planks at positions not occupied by the decorative motifs and/orembossed surface textures of partial sub-panels of a plank allowscomplementary partial sub-panels to appear as a part of a unitarysub-panel while not significantly detracting from the overall durabilityof each of the planks. In yet another aspect of the present invention,portions of the surface of each plank may be recessed at locations wheresub-panels of a plank are adjacent one another. Referring to FIG. 13B,portions of the upper surface of each of the planks 130 indicated byreference numeral 138 c may be slightly recessed compared to the majorsurface of each of the planks (see also FIG. 12B) to provide a visualand textural effect that each of the sub-panels of the plank are not apart of the same plank.

FIGS. 14A-14C illustrate an exemplary plank of a flooring system instill another aspect of the present invention.

Referring to FIGS. 14A-14C, similar to the plank shown in FIGS. 13A and13B, portions of the upper surface of the perimeter “P” of each of theplanks 130 indicated by reference numeral 138 a may be beveled toprevent premature wear of each of the planks. Further, portions uppersurface of the perimeter of each of the planks 130 indicated byreference numeral 138 b may not be beveled such that they aresubstantially coplanar with the major surface of the sub-panels.Beveling the perimeter surface of each of the planks at positionscorresponding to the decorative motifs and/or embossed surface texturesof partial sub-panels of a plank allows complementary partial sub-panelsto appear as a part of a unitary sub-panel while not significantlydetracting from the overall durability of each of the planks. In yetanother aspect of the present invention, portions of the surface of eachplank may be provided with a groove at locations where sub-panels of aplank are adjacent to one another.

FIGS. 14B and 14C illustrate cross-sectional views of plank 130 takenacross lines I-I′ and II-II′, respectively. Referring to FIGS. 14B and14C, portions of the upper surface of each of the planks 130 indicatedby reference numeral 138 c may be beveled to form a groove. Thus, thegroove provides a visual and textural effect that sub-panels of a plankare separate. In one aspect of the present invention, the bevel at 138 cmay produce a groove having a substantially V-shaped groove. It isappreciated, however, that the bevel may produce other groovetopographies (e.g., U-shaped grooves, etc.). In one aspect of thepresent invention, the beveling of each of the planks 130 at perimetersurface portion 138 a creates a groove between adjacent planks.Accordingly, the groove formed between adjacent ones of the planks, viabeveling at 138 a, has substantially the same width and topography asgrooves formed within the planks, via beveling at 138 c.

The motif and/or surface texture present at the recessed surface of theperimeter of each plank may or may not correspond to the motif/surfacetexture present at the main surface of a corresponding plank. Thus, asubstantially continuous motif and/or surface texture may or may not bepresent across the surfaces of the perimeter and the interior of anyindividual plank. Alignment marks or markings (not shown) can be used toself-align a decorative motif on the planks. In one aspect of thepresent invention, the embossed in-registration pattern may be a freeform or custom design. It is to be understood that substantially anyembossed-in-registration pattern and any decorative motif may berealized by applying the principles of the present invention. In oneaspect of the present invention, alignment of the planks may be donevisually upon joining them together. Accordingly, alignment of theplanks 130 may be performed using the decorative motif and/or embossedsurface texture of each of the planks.

While it has been illustrated that the planks in FIGS. 13A, 13B, and14A-14C are substantially rectangular, the principles of the presentinvention allow the planks within the flooring system to have othershapes and sizes (e.g., geometric, freeform, etc.) or different orsimilar dimensions such that the flooring planks may be assembled in a“mosaic”-type arrangement or other regular, semi-repetitious, or randomarrangement of panels. Further, while it is illustrated that each plankcomprises an identical sub-panel layout, the principles of the presentinvention allow the planks within the flooring system to have othersub-panel layouts (e.g., other sub-panel shapes, sizes, etc.) Theindividual planks within the flooring system may be cut from a boardsuch that joints between the flooring panels of the flooring system arenot visible. Further, the planks within the flooring system illustratedin FIGS. 13 and 14 may be joined together with or without glue. Stillfurther, while it has been discussed that the embossed surface textureis substantially aligned with an underlying decorative motif, it is tobe understood that substantially any embossed surface texture may beimparted to the planks of the present invention, regardless of theunderlying decorative motif. Still further, the decorative motifs and/orthe embossed surface texture of one plank may not be aligned or even beremotely similar in appearance and/or texture to decorative motifsand/or embossed surface textures of adjacent planks.

According to the principles of the present invention, any of theaforementioned decorative motifs and/or embossed surface textures thatmay or may not be embossed in registration with the decorative motifs(collectively referred to herein as “patterns”) may be applied to any ofthe aforementioned planks to form a substantially continuous patternacross adjacent planks arranged along a predetermined direction byforming each of the plank patterns using at least one bulk pattern andat least one edge pattern.

In one aspect of the present invention, each edge pattern may be presentat a perimeter portion of the plank extending along at least a portionof at least one edge of each plank. In another aspect of the presentinvention, each edge pattern may extend to a predetermined distance(e.g., about one millimeter, about one inch, etc.) into the interior ofthe plank, away from the perimeter of the plank. In another aspect ofthe present invention, at least one bulk pattern may be arrangedadjacent at least one edge pattern, wherein a pattern present at theedge of the bulk pattern adjacent the edge pattern may form asubstantially continuous visual/textural pattern with a pattern presentat the edge of the edge pattern adjacent the bulk pattern.

In one aspect of the present invention, patterns of individual planks,arranged adjacent each other along a predetermined direction within aflooring system, may complement patterns of adjacent planks (i.e., formsubstantially continuous patterns across adjacent planks) when edgepatterns of the adjacent planks form a substantially continuous pattern.Where the flooring system described above comprises a plurality ofadjacent planks arranged along the predetermined direction, and wherethe edges of each plank are arranged adjacent to edge patterns of otherplanks along the predetermined direction, edge patterns of adjacentplanks are identical or substantially identical. The identical orsubstantially identical edge patterns of adjacent planks enable acontinuous pattern to be formed across the adjacent planks.

For example, referring to FIG. 15A, an exemplary plank pattern of plank150 may comprise two edge patterns 152 substantially identical to eachother and a bulk pattern 154. As shown in FIG. 15A, the twosubstantially identical edge patterns 152 are present at a perimeterportion of the plank 150, extend along a portion of the opposite edgesof the plank, and extend a predetermined distance into the interior ofthe plank 150. Still referring to FIG. 15A, the pattern present at theedge of the bulk pattern 154 adjacent the edge patterns 152 forms asubstantially continuous pattern with the pattern present at the edgepatterns 152 adjacent the bulk pattern.

Referring now to FIG. 15B, a plurality of planks 150A, 150B, 150C, etc.,such as those illustrated in FIG. 15A may be arranged adjacent eachother within a flooring system along a predetermined direction such thatedges of each plank are arranged adjacent to the edges of other planksalong the predetermined direction (e.g., an edge of plank 150A isadjacent an edge of plank 150B, an edge of plank 150C is adjacent anedge of plank 150D, etc.). As mentioned above, a substantiallycontinuous pattern may be formed across an individual plank 150 becausethe bulk pattern 154 is substantially aligned with the edge patterns152.

In an embodiment of the invention, the predetermined direction in whichthe planks are arranged is based on the adjacent edge patterns 152 inthe planks, such that only by arranging the planks in the predetermineddirection will the pattern formed be continuous and natural-looking. Inthis embodiment, reversing a plank or flipping a plank over will resultin a discontinuous pattern. However, it is understood that in anotherembodiment, the edge patterns along a portion of the perimeter may beselected such that reversing, flipping or otherwise rearranging planksdoes not disrupt the pattern, i.e. the pattern is continuous.

In another embodiment, the predetermined direction is based on theinterlocking mechanism that joins adjacent planks, such that the plankswill not fit together properly if they are arranged in a direction otherthan the predetermined direction. One example of such a interlockingmechanism is a glueless tongue and groove system, in which the tongue isformed along at least one edge of the plank and the groove formed alongthe opposite edge. In yet another embodiment, the predetermineddirection is based on both the edge patterns 152 and the gluelesslocking mechanism.

According to the principles of the present invention, bulk patterns154A-154F may or may not be the same. In one aspect of the presentinvention, each of the bulk patterns 154 within a flooring system may beunique. Further, according to the principles of the present invention,edge patterns of individual planks may be substantially identical.Therefore, edge patterns of adjacent planks in a flooring system, acrosswhich a substantially continuous pattern is formed along thepredetermined direction, are also substantially identical. Asubstantially continuous pattern may be provided across plank 150Abecause bulk pattern 154A and edge patterns 152A are aligned with eachother to produce a substantially continuous pattern. Substantiallycontinuous patterns may be individually provided across planks 150B,150C, etc., because their respective bulk patterns 154B, 154C, etc., andedge patterns 152B, 152C, etc. are similarly aligned with each other toproduce a substantially continuous pattern.

Because the edge patterns of planks 150A-150F within the flooring systemillustrated in FIG. 15B are identical, edge pattern 152A forms asubstantially continuous pattern with edge pattern 152B, edge pattern152C forms a substantially continuous pattern with edge pattern 152D,and so on. Accordingly, a substantially continuous pattern may be formedacross planks 150A and 150B, across planks 150C and 150D, and so on. Theboundary or joint between the edge pattern 152A and the edge pattern152B is substantially not visible, or the appearance of the presence ofthe boundary or joint is minimized. Similarly, the boundary or jointbetween the edge pattern 152C and the edge pattern 152D is substantiallynot visible, or the appearance of the presence of the boundary or jointis minimized. The boundary or joint between the edge pattern 152E andthe edge pattern 152F is substantially not visible, or the appearance ofthe presence of the boundary or joint is minimized.

In one embodiment of the present invention, in which the edge patterns152 are all substantially identical, any of the planks 150A-150F mayreplace any other plank within the flooring system while stillmaintaining the presence of a substantially continuous pattern acrossplanks arranged adjacent each other along the predetermined direction.This is because all bulk patterns of a plank are substantially alignedwith their respective edge patterns to form substantially continuouspatterns within a plank and because all edge patterns of planks adjacenteach other within a flooring system are identical, forming formsubstantially continuous patterns across planks adjacent each otheralong the predetermined direction.

In another embodiment, planks may have adjacent right and left edgepatterns 152 substantially identical, while opposite left and right edgepatterns 152 are not.

For example, in FIG. 15C, the unitary sub-panel 132 of plank 150 mayhave a pattern provided by a bulk pattern 154G, partial sub-panel 134may have a pattern provided by bulk pattern 154I and edge pattern 152,and partial sub-panel 136 may have a pattern provided by bulk pattern154H and edge pattern 152, wherein the bulk patterns 154G-154I may ormay not be the same. As mentioned above, however, the edge pattern 152,present at the perimeter of the partial sub-panel portions 134 and 136of the plank 150 and extending along a portion of the edges of the plank150, are identical to each other. Accordingly, in view of FIG. 13A,when, for example, planks 130A and 130B are arranged adjacent each otheralong a predetermined direction, edge patterns 152 of complementarypartial sub-panels 134A and 136B are substantially identical to eachother and a substantially continuous pattern may be formed acrossadjacent planks, wherein the bulk patterns of the complementarypartial-sub panels become a part of a substantially continuous pattern,appearing, visually and/or texturally as a unitary sub-panel.

Furthermore, referring now to FIGS. 15C and 15D, flooring systemsincorporating planks such as those illustrated in FIGS. 13A-14C may beprovided with substantially continuous patterns across planks adjacenteach other along predetermined directions by applying the techniquesdescribed above with reference to FIGS. 15A and 15B. FIG. 15D shows theplanks having a woodgrain pattern in the arrangement shown in FIG. 15B.Because the edge pattern 152A is substantially identical to the adjacentedge pattern 152B, planks 150A and 150B have the appearance of asubstantially continuous woodgrain pattern running uninterrupted acrossthe boundary or joint between edge pattern 152A and edge pattern 152B ofthe adjacent plank.

In addition, because the edge patterns 152A and 152B do not run alongthe entire length of the boundary or joint between planks 150A and 150B,but only along the portion corresponding to the height of the partialboard on the bottom half of the planks, the pattern is not continuousacross that portion of the boundary between planks 150A and 150Bcorresponding to the height of the complete boards on the top half ofthe planks.

As mentioned above, within the flooring system incorporating the planksillustrated in FIGS. 13A-14C and 15C, the bulk patterns within thesub-panels of the planks may or may not be the same. In one aspect ofthe present invention, each of the bulk patterns within the flooringsystem may be unique.

FIG. 15E shows an embodiment of the invention in which the edge patternsof the planks are identical (or substantially identical) in every plank.Specifically, FIG. 15E shows four planks, 150A, 150B, 150C, and 150Darranged such that plank 150A is adjacent the left edge of plank 150Band adjacent to a top edge of plank 150C. Plank 150D is adjacent to theright edge of plank 150C and adjacent to the bottom edge of 150B.

In this embodiment, the décor paper of each plank has a wood design.However, it is understood that other natural looking designs other thanwood are contemplated by this invention as well. The wood design inplank 150A includes, for example, a complete board or strip 155A on atop half of the board, a short incomplete board 151A and a longincomplete board 153A. Each of the boards has a woodgrain pattern. Inaddition, the short and long incomplete boards 151A and 153A have anedge pattern 152 running along a portion of the perimeter of the plankcorresponding to the width of the incomplete boards 151A and 153A, andmay extend a small distance (such as one centimeter, for example) intothe interior of the boards. The edge patterns 152 of incomplete boards151A and 153A are identical. The edge patterns 152 may also not extendinto the interior of the boards.

Similarly, planks 150B, 150C, and 150D have complete boards 155B, 155C,and 155D, respectively, running the length of the plank, and shortboards 151B, 151C, and 151D which are adjacent to long boards 153B,153C, and 153D, respectively. Each of the short and long boards may havean identical edge pattern 152 along a portion of the perimeter of theplank corresponding to the width of the short and long boards.

All short boards 151A-D, long boards 153 A-D, and complete boards 155A-Dhave woodgrain patterns that are different from each other or someidentical to each other. Only the edge patterns 152 in the incompleteboards are identical in this particular example. Furthermore, the edgepattern and interior woodgrain pattern of each incomplete board form acontinuous pattern. In other words, there is a continuous overallwoodgrain pattern on each of the short boards and long boards that areall different from one another, despite the fact that the edge patterns152 are the same.

When planks 150A and 150B are placed adjacent to one another as shown inFIG. 15E, complete boards 155A and 155B will be adjacent to each other,and long board 153A and short board 151B will be adjacent. Completeboards 155A and 155B appear as separate boards and the woodgrain patternis discontinuous across them, because the adjacent edges of the completeboards are different. But because the edge patterns 152 in long board153A and short board 151B are the same, the unique woodgrain patterns of153A and 151B appear to form a single continuous board with a uniquewoodgrain pattern running across the planks 150A and 150B. Furthermore,the appearance of a complete and continuous board with a uniquewoodgrain pattern running in boards 153A and 151B across the planksminimizes the visibility or appearance of the joint or boundary betweenthe planks. Similarly, the woodgrain pattern across boards 153C and 151Dis continuous.

In a further embodiment, the planks 150A, 150B, 150C, and 150D may havea surface texture that is embossed in registration with the wood designon the décor paper. Because edge patterns 152 are part of that wooddesign and may be the same or substantially identical in every plank,the embossed surface texture will appear to be continuous along theincomplete boards of adjacent planks in the manner discussed above. Instill another embodiment, the embossed in registration surface texturemay include bevels to imitate seams between boards, such that in plank150A, for example, the complete board 155A would have a bevel runningalong its perimeter, including the boundary between board 155A andincomplete boards 151A and 153A. The incomplete boards 151A and 153Awould have a bevel where they are adjacent, but the incomplete boardswould not have a bevel along the portion of the perimeter of the plank150A where the edge patterns 152 are located. In this way, a continuouswood grain pattern and corresponding embossed in registration surfacetexture can run continuously across planks 150A and 150B uninterruptedby a bevel. This would further reduce the appearance of the boundarybetween planks.

By having all edge patterns 152 to be identical, the present inventionallows any planks to be fit together in the predetermined direction inwhich a long board 153 is adjacent a short board 151 of another plank,because the edge patterns 152 will always line up to form the appearanceof a continuous wood grain pattern running across the adjacent long andshort boards of the two planks. For example, if the positions of planks150A and 150B were reversed (such that plank 150B was adjacent a topedge of plank 150C), the edge pattern 152 of long board 153B would matchor be aligned with the edge pattern of short board 151A, forming acontinuous wood grain pattern in the boards 153B and 151A across planks150B and 150A.

The present invention reduces the complexity involved in installing alaminated floor, because it does not matter which planks are placedadjacent to one another in the predetermined direction. The patternswill be aligned. In a further embodiment, the planks 150 are providedwith a glueless interlocking tongue and groove system in which thetongue is formed on two adjacent perimeter edges of the plank and thegroove is formed in the opposite two adjacent perimeter edges so thatthe planks can only be fit together in the direction that will alignlong boards 153 with short boards 151, for example, where edge patterns152 meet.

In the exemplary embodiment discussed above, the decorative motifs anddesign pattern elements such as wood strips run across separate adjacentplanks. However, the wood strip motif has a length equal to that of thelength of the plank, in order to allow for the interchangeability ofplanks, ensuring an easy installation.

FIG. 16 illustrates another exemplary embodiment of the presentinvention. In this embodiment, a flooring system including at least twodistinct planks 160 and 161 has a wood grain motif that includes designmotifs imitating wood strips. The flooring system has wood strip motifsrunning across adjacent planks and that may have a total length equal totwice the length of a single plank. In particular, the flooring systemillustrated in FIG. 16 includes a first plank 160 and a second plank161. The first plank 160 includes a top wood strip 164 and a bottom woodstrip 165. On a first edge of the top wood strip 164 is an edge pattern162 chosen to continue the wood grain pattern from wood strip 164 overto an adjacent plank. The bottom wood strip 165 includes an edge pattern163 at the edge of the strip on the side of the plank opposite the edgeof the plank where edge pattern 162 on the top strip 164 is situated.Edge pattern (also referred to as “continuous pattern”) 163 similarlycontinues the wood grain pattern from the bottom strip 165 across overto an adjacent plank. In alternative aspects of this embodiment, edgepatterns 162 and 163 may be different or may be identical.

As noted earlier, a variety of materials may be used to make the planksof the present invention. The materials may include real wood, wood orplastic composites such as particle board, chip board, or laminates. Theplanks may also include a décor paper or hardwood veneer that includesthe decorative patterns. In alternative embodiments, the planks may bemade of one species of solid wood with a different species of solid woodveneer on the surface that is precisely cut so that the edge patternsalign as discussed herein.

The wood strips have bulk patterns in the portions of the strip otherthan the edges. The bulk pattern corresponds to the underlying designpattern. In other words, the bulk pattern may be a wood grain, stone,marbling, or some other pattern. The edge patterns 162 and 163 arecontinuous with the bulk pattern such that the edge pattern and the bulkpattern from a continuous pattern. The seam patterns 168 and 169 are notcontinuous with the bulk pattern, but rather are discontinuous, so as toenhance the appearance of a discontinuity between adjacent bulk patternshaving the discontinuous pattern between them.

Second plank 161 includes a top strip 166 and a bottom strip 167. Thetop strip 166 includes the edge pattern 162 at the edge of the plankopposite the edge where the edge pattern 162 is located on the top strip164 of the first plank 160. Likewise, bottom strip 167 includes an edgepattern 163 along the edge of the plank 161 opposite the edge where theedge pattern 163 is located on the first plank 160. Other embodimentsmore strips in addition to the top and bottom strip.

The first wood strip 160 includes a decorative motif intended torepresent a seam between the decorative motifs of the wood strips. Inthe top strip 164 there is a seam pattern 168 on the edge of the plankopposite the edge where edge pattern 162 is situated and there is acomplete seam pattern 169 between the top strip 164 and the bottom strip165. Furthermore, there is a seam pattern 168 on an edge of the bottomstrip 165 opposite the edge of the bottom strip where edge pattern 163is situated.

Similarly, in the second plank 161 there is a seam pattern 168 on theedge of the plank opposite the edge where edge pattern 162 is situatedand there is a seam pattern 168 on the edge of the plank opposite theedge where seam pattern 163 is situated. Furthermore, a seam 169 runsbetween the top strip 166 and the bottom strip 167.

The seams 168 may be complete width seams, i.e., their width may be thesame as the thickness of the seam pattern 166 or, in an alternativeembodiment, the width of the seam pattern 168 may be half the width ofthe width of the seam pattern 169 such that when two adjacent seampatterns 168 are placed adjacent one another they form a seam patternwhose thickness is equal to the thickness of seam pattern 169.

When the flooring plank 160 is placed adjacent to flooring plank 161 thebottom strips 165 and 167 are adjacent to one another and the edgepatterns 163 on edges of the plank at the opposite ends of the woodstrips 165 and 167 abut one another to form a continuous wood stripdesign flowing across wood plank 162 and wood plank 161 creating a woodstrip whose length is twice the length of the floor planks 160 or 161.The wood strip runs from one end of the flooring plank 160 across to thedistal edge of the second plank 161. If an additional first flooringplank 160 is placed on the other side of the second flooring plank 161then the top flooring plank 166 of the second flooring plank 161 wouldbe adjacent to the top wood strip 164 of the first flooring plank 160such that the edge patterns 162 and the top strips 166 and 164 abut oneanother thereby creating a wood strip flowing across the tops ofadjacent flooring planks 161 and 160 that is twice the length of theindividual flooring planks. Thus, using only two distinct planks theflooring system of the present invention is able to reproduce a woodstrip design in which the length of the wood strip motif is twice thelength of the plank.

In alternative aspects of the embodiment, the seam patterns 168 at theedges of the plank are replaced by a pattern discontinuous from the bulkpattern in the center of the strip but which aligns with thecorresponding discontinuous pattern on an adjacent plank.

The present invention is not limited to wood grain patterns, but alsocontemplates stone and marble patterns as well as artificial or artisticdesigns. In another exemplary embodiment using a marble pattern ratherthan a wood grain pattern, edge patterns 162 and 163 may be portions ofmarbling that align with the corresponding edge pattern of an adjacentplank to form continuous marbling across planks, creating the effect ofa marble strip or tile longer than the physical length of the plank.

In further embodiments, the present invention includes beveled edges andembossed-in-registration surface textures in addition to the décorpattern. In particular, a bevel can be embossed or cut overtop the seampatterns 168 and 169 such that the bevel has the same width as the seampattern, thereby further enhancing the optical effect of separatedboards. Furthermore, the planks 160 and 161 may also have a surfacetexture embossed-in-registration with the décor pattern such that theembossed-in-registration texture includes corresponding surface texturesfor the edge patterns 162 and 163. In this manner, theembossed-in-registration surface textures continue across from one plankto the next. In addition, because the flooring system only has twodistinct planks, installation of the planks is simple. They planks areinstalled in an alternating fashion such that flooring plank 160alternates with flooring plank 161 in a horizontal direction to createwood strips whose length is twice the length of a flooring plank in suchthat the wood strips at the top and the bottom of the planks arestaggered.

The present invention contemplates further embodiments such as theexemplary embodiment illustrated in FIG. 16B in which the flooringsystem includes as many as four distinct flooring planks. These fourflooring planks include the first and second flooring planks 160 and 161illustrated in FIG. 16A as well as two additional flooring planks 171and 172. Third flooring plank 171 includes a top strip 173 and a bottomstrip 174. Here, the top strip 173 has a seam pattern 168 on both edgesof the plank while the bottom strip 174 has the edge pattern 163 on bothends of the plank. In addition, the fourth plank 172 has a top strip 175and a bottom strip 176 in which the top strip 175 has edge pattern 162on both ends of the plank but bottom strip 176 is bounded by seampatterns 168. In this flooring system planks may be placed adjacent oneanother provided that they have seam patterns 168 that will be adjacentone another in one strip and an edge pattern 162 or 163 that will beadjacent in the two planks as well when the two planks are placedadjacent one another. As noted earlier, the seam patterns 168 may bereplaced by patterns other than seams that are discontinuous from thebulk pattern in the center of the strip.

In this exemplary embodiment, illustrated in FIG. 16B, plank 160 maybeplaced adjacent to flooring planks 171 or 161 on a first side of planks171 and 161 (the left hand side in FIG. 16B) or it may be placedadjacent planks 161 and 172 on a second side of planks 161 and 172 (theright hand side in FIG. 16B). Likewise, flooring plank 171 may be placedadjacent planks 160 or 161 on the first or left side or may be placedadjacent to another plank 171 on either the first (left) or second(right) side. Plank 161 may be placed to the right of plank 160 or plank171 or to the left of plank 172 and 160. Finally, plank 172 may beplaced to the right of plank 161 or to the right of another plank 172 orto the left of plank 160 or to the left of another plank 172. Thisprovides for a number of combinations and arrangements of the fourflooring planks thereby providing a number of wood strips in the overallflooring pattern design having different lengths greater than or equalto the length of a single flooring plank. For example, if planks 160,171, 161 and 172 are placed adjacent one another in the mannerillustrated in FIG. 16B then the resulting flooring design will includewood strips of length equal to the length of a single plank in flooringplanks 171 and the bottom of plank 172. However, the flooring designwill also include wood strips whose length is equal to three times thelength of a flooring plank such as the wood strip running from thebottom strip of plank 160 across the bottom strip plank 171 and acrossthe end of the bottom strip of plank 161 to the distal end of the plank161. In addition, planks 171 or 172 may be repeated adjacent to oneanother as often as is desired to further increase the length of thewood strip in the flooring design to several multiples of the length ofa single plank. This is possible because planks 171 and 172 provide woodstrips 174 and 172 respectively that are not bounded on either side bydiscontinuous seam patterns 168 or 169, but rather have the same edgepattern 163 or 162 on either side. This way the flooring systemillustrated in FIG. 16B, having the flooring planks 160, 161, 171 and172, is able to provide wood strips of variable long length withoutincreasing the complexity of the overall flooring plank system.

Specifically, the installer is able to install any flooring plankadjacent any other flooring plank such that there will be an edgepattern or discontinuous pattern (such as seam pattern 168) in the topstrip or in the bottom strip that is adjacent to the correspondingpattern in the corresponding strip of the adjacent plank. Thus theinstaller has the ability to design a flooring pattern using the fourdistinct planks of the system knowing that the complexity of theinstallation does not increase beyond the requirement that seam patterns168 be placed adjacent to another seam pattern 168 or that a seampattern 169 be placed adjacent to another pattern 169.

The flooring system can be simplified further to require only threedistinct planks: planks 160, 161, and either of planks 171 or 172. Forexample, in an embodiment with planks 160, 161, and 171, any number ofplanks 171 can be placed between planks 160 and 161, as is shown in FIG.16B to create a very long wood strip formed by adjacent bottom strips165, multiple 174, and 167. In addition, planks 160 and 161 may also beplaced adjacent to one another. To create wood strip patterns of lengthequal to twice the length of a plank across either two top or two bottomwood strips. Furthermore, because in this embodiment only the edgepatterns are required to be identical, the interior patterns of thecomplete, long and short boards of the planks can be different,providing a more natural looking floor.

The number of planks in the flooring system can be further reduced totwo planks. FIG. 16C illustrates another embodiment having two planks181 and 182. The first plank 181 includes a discontinuous pattern 183,patterned as a seam, an upper edge pattern 184 corresponding to the topwood strip of the plank 181, and lower edge patterns 185 on oppositesides of the lower wood strip. The second plank 182 includes an edgepattern 184 on the top strip of the plank on the edge opposite thelocation of the edge pattern 184 on the first plank 181. A discontinuouspattern 183 is located on the edge of the plank opposite that where theedge pattern 184 is located. The bottom strip of the plank 182 includesedge patterns 185 on the opposite edges of the plank 181 with twoadjacent discontinuous patterns located in the interior of the bottomstrip between the edge patterns 185.

When the first and second plank are placed adjacent one another in ahorizontal direction such that the edge patterns 184 or 185 of differentstrips are adjacent to one another, the result is a staggered pattern ofwood strips whose length is twice the length of the plank.

In a further embodiment, illustrated in FIG. 16D, two planks 186 and 187have an arrangement of edge patterns 184 and 185 and discontinuouspatterns 183 different from that of the two planks in FIG. 16C. Inparticular, first plank 186 has edge patterns 184 at both ends of thetop strip with adjacent discontinuous patterns 183 there between, andedge patterns 185 on both ends of the bottom strip also with adjacentdiscontinuous patterns 183 there between. The second plank 187 as a topstrip with edge patterns 184 at both ends and a bottom strip with edgepatterns 185 at both ends. The second strip 187 does not include anydiscontinuous patterns. By placing planks 186 and 187 adjacent to andalternating with one another, the result is a flooring design withstaggered wood planks whose length is twice the length of the plank. Inaddition, because in this embodiment the plank 187 has no discontinuouspatterns, multiple planks 187 can be placed adjacent to one another toextend the length of the wood strips to any multiple of the length ofthe plank.

It is understood in the embodiments of FIGS. 16C and 16D that the edgepatterns 184 and 185 may be the same or they may be different.Furthermore, it is understood that the planks are not required to havemore than one strip as part of their design pattern. For example, FIG.16E illustrates an embodiment having two planks 188 and 189 each havingonly a portion of one strip. Plank 188 has a discontinuous pattern 183at a first end of the plank and a continuous edge pattern 184 at theopposite second end of the plank. Plank 189 has a discontinuous pattern183 at the second end and the continuous edge pattern 184 at the firstend of the plank. Thus, planks 188 and 189 may be placed adjacent oneanother in the horizontal direction to create a single strip design inwhich the length of the strip is twice the length of the plank, and thewidth of the strip is equal to the width of the plank.

A further exemplary embodiment, illustrated in FIG. 17, includes planks188 and 189 as illustrated in FIG. 16E, but in addition includes thirdplank 190 and fourth plank 191. The third plank 190 includesdiscontinuous patterns 183 along all edges of the plank, and fourthplank 191 includes the continuous edge patterns 184 at both ends of theplank.

With four such distinct planks, the flooring design may have strips oflength substantially equal to the length of one plank, two planks, orthree or more planks, depending on the number of duplicate third planksare placed adjacent one another. In an exemplary arrangement, planks areplaced adjacent one another in multiple rows in the order of first plank188, second plank 189, fourth plank 191, and third plank 190.

Four planks 188-191 have a further advantage in that planks may bemanufactured using a décor paper which is pressed and cut into plankswhich are then packed in to cartons for shipping and sale. In décorpaper that is wide enough to accommodate four planks, it is reasonableto have four distinct planks on a single décor paper. This way, theplanks are pressed onto a board, embossed, cut into planks together, andshipped together in the same carton.

FIG. 18 illustrates an embodiment of the invention in which a flooringsystem includes four flooring planks. The flooring system includes fourplanks, 200, 202, 204, and 206 each of which has a surface designpattern including to long horizontal strips. Planks 200, 204 and 206have similar strip arrangements. In the bottom portion of the planks isa single complete strip 205 with discontinuous edge patterns 203 oneither side of the strip at the ends of the plank. The particularpattern, such as a wood grain pattern, of the single complete strips205A, C, and D may be the same or different on each of the planks 200,204, and 206, respectively.

In the upper portion of the planks are two incomplete strips 208 and209, adjacent to one another, separated by a discontinuous pattern 207that resembles a seam or a joint. The particular pattern, such as a woodgrain pattern, of the incomplete strips 208A, C, and D and theincomplete strips 209A, C, and D may be the same or different on each ofthe planks 200, 204, and 206, respectively. Some portion at the edge orend of the plank, where the incomplete strips 208 and 209 meet the endof the plank, is a continuous edge pattern 201 that is the same on allfour planks 200, 202, 204 and 206. The continuous edge pattern 201 iscontiguous and continuous with the overall, or bulk, pattern of thestrips 208 and 209, however, while the bulk patterns of the incompletestrips 208A, 208C, 208D, 209A, 209C, and 209D may be different, thecontinuous edge pattern is the same. This way, when any of planks 200,202, 204 and 206 are placed adjacent one another, the continuous edgepatterns of the adjacent incomplete strips of different planks, such as209A and 208C for example, align to create the appearance of a single,complete strip that runs across the upper portion of more than oneplank.

The discontinuous pattern 207 may be the same as discontinuous pattern203, it may be similar to two discontinuous patterns 203 placed adjacentone another, or it may be entirely different from discontinuous pattern203. Planks 200, 204, and 206 differ in the horizontal position of thediscontinuous pattern 207 along the upper portion of the planks. Inother words, the length of the pairs incomplete strips, 208 and 209, maydiffer in each of planks 200, 204, and 206. For example, the lengths ofthe incomplete strips 208C and 209C of plank 204 are different than thelengths of the incomplete strips 208D and 209D of plank 206. Therefore,while planks 200, 204, and 206 have the same arrangement of continuousedge patterns 201, discontinuous edge patterns 203, incomplete andcomplete strips 208 and 209, the length of those incomplete strips isdifferent. This way, a floor made of the planks 200, 202, 204 and 206will appear to have a more random and natural looking appearance becauseof the differing lengths of complete strips formed by placing incompletestrips adjacent one another.

As illustrated in FIG. 18, the flooring system may also include a plank202 having one complete strip 205B in the bottom portion of the plank202 bounded at the ends of the plank by the discontinuous edge pattern203 and a single incomplete strip 210 in the upper portion of the plank202 incorporating within it the continuous edge pattern 201 at a portionnear the edge of the plank. Plank 202 may be used to extend the apparentlength of the incomplete strip by one plank length. For example, ifplanks 200, 202, and 204 are placed adjacent one another, they willcreate the appearance of three complete strips of equal length with along complete strip above them. Furthermore, because the placement ofthe discontinuous pattern 207 is different in planks 200 and 204, thelength of that long complete plank will not be equal to a multiple ofthe plank length.

FIG. 19 illustrates a further alternative embodiment of the invention,in which a flooring system includes four planks 220-223. Three of theplanks, 221-223, each include a discontinuous pattern 224 in a differentposition in their decorative pattern, thereby forming two incompletestrips 226A and 227A, 226B, and 227B, and 226C and 227C, respectively.The length of the incomplete strips 226 and 227 differs among the planksbecause of the differing placement of the discontinuous pattern 224. Oneof the planks, plank 220, does not include the discontinuous pattern224, and therefore has a decorative pattern that forms only a singleincomplete strip. A portion of the decorative pattern near the edge ofthe plank, forms a continuous edge pattern 225 that is the same on bothsides of all four planks 220-223 in the flooring system. The continuousedge pattern is contiguous and part of the overall decorative pattern onthe plank, and when placed adjacent another edge pattern on anotherplank, continues the decorative pattern seamlessly from one plank to thenext. Using a flooring system having the four distinct planksillustrated in FIG. 19, a floor pattern can be created in which woodstrips may have a variety of lengths, including lengths that are greaterthan one or two plank lengths, but which may not be multiples of a planklength.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the invention. Thus, it isintended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. A flooring system comprising: a plurality of distinct flooringplanks, at least a first and second plank of said plurality having afirst edge pattern along a portion of an edge of the plank and a secondedge pattern running along the remainder of the portion of that edge ofthe plank, wherein the first and second edge patterns are placed on theside of the first plank opposite the side where the first edge patternand the second edge patterns are located in the second plank, whereinthe positions of the first and second edge patterns on one edge of thefirst plank are different from the positions of the first and secondedge patters on the opposite edge of said first plank.
 2. The flooringsystem of claim 1, further comprising a bulk pattern in an interiorregion of said first plank.
 3. The flooring system of claim 1, whereinthe first edge pattern further comprises a portion of a décor patterncontinuous with said bulk pattern and wherein the second edge patterncomprises a discontinuous pattern.
 4. The flooring system of claim 2,wherein the décor pattern of the first edge pattern is a wood grainpattern and wherein the discontinuous pattern is a seam.
 5. The flooringsystem of claim 1, further comprising a third plank wherein the thirdplank has the first edge portion running along the same portion on bothedges of the plank and a second edge portion running along the sameother portion of both edges of the planks.
 6. The flooring system ofclaim 4, further comprising: a fourth flooring plank having a first edgepattern along the portion of both edges of the plank, said portiondifferent from the portions of the third plank where the second edgepattern is located.
 7. The flooring system of claim 1 wherein the firstedge pattern and the second edge pattern are different from one another.8. The flooring system of claim 1, wherein the first edge pattern andthe second edge pattern are the same height but are on opposite sides ofthe first and second flooring plank.
 9. A flooring system comprising aplurality of planks, each of said planks having a plurality of edgepatterns disposed along edges of the flooring plank such that each ofsaid edge patterns is positioned along the opposite edges of theflooring planks such that the edge patterns on any one of said pluralityof planks aligns with the edge patterns of at least two other of saidplurality of flooring planks when said two other flooring planks areplaced adjacent said first flooring plank.
 10. The flooring system ofclaim 9 wherein at least one of said plurality of distinct planks has anarrangement of said edge patterns in which the arrangement of theplurality of edge patterns on one side of the plank matches thearrangement of the edge patterns on the opposite side of the plank. 11.The flooring system of claim 9 wherein at least one of said plurality ofdistinct planks includes an arrangement of said edge patterns on oneside of the plank that is opposite the arrangement of said edge patternson the opposite side of the plank.
 12. A flooring system comprising: afirst plank; a second plank; a first edge pattern at a portion of afirst edge of said first plank and at a portion of a second, opposite,edge of said second plank; and a second edge pattern at a portion of thesecond edge of said first plank and at a portion of the first edge ofsaid second plank.
 13. The flooring system of claim 12, furthercomprising: the second edge pattern at a portion of the first edge ofsaid first plank substantially opposite the portion of the second edgeof said first plank where said second edge pattern is located.
 14. Theflooring system of claim 13, further comprising: the first edge patternat a portion of the second edge of said first plank substantiallyopposite the portion of the first edge of said first plank where saidfirst edge pattern is located.
 15. The flooring system of claim 13,further comprising: a discontinuous pattern between said second edgepatterns of said first plank.
 16. The flooring system of claim 12,wherein said first edge pattern is a discontinuous pattern.
 17. Theflooring system of claim 15, further comprising: a discontinuous patternbetween said first edge patterns of said first plank.
 18. A buildingpanel system, comprising: a plurality of distinct planks having aninterior décor pattern; each of said planks having a first edge and asecond edge opposite said first edge; a continuous edge pattern on atleast a portion of said first edge of at least two of said plurality ofdistinct planks; a continuous edge pattern on at least a portion of saidsecond edge of at least two of said plurality of distinct planks; adiscontinuous edge pattern on at least a portion of said first edge ofat least two of said plurality of distinct planks; and a discontinuousedge pattern on at least a portion of said second edge of at least twoof said plurality of distinct planks.
 19. The building panel system ofclaim 18, wherein at least one distinct plank of said plurality ofdistinct planks has a continuous edge pattern along the entire first andsecond edges of said plank.
 20. The building panel system of claim 18,said distinct planks further comprising a third edge and a fourth edgeopposite said third edge, wherein a continuous edge pattern is along atleast a portion of said third edge.
 21. The building panel system ofclaim 20, further comprising: a continuous edge pattern along at least aportion of said fourth edge, wherein none of said continuous edgepatterns on said first, second, third, or fourth edges are adjacent anyother continuous edge pattern on a different edge.
 22. The buildingpanel system of claim 18, wherein said building panel system is aflooring panel system, and said planks are flooring planks.